Junction box for a photovoltaic module mounting assembly

Abstract

The present disclosure provides junction boxes for use with roof-mounted photovoltaic (PV) modules. The junction boxes may include a housing having a plurality of sides, a bottom having an aperture, and a top edge having a top opening, where the top edge has a lip disposed around the top edge and projecting upward from the top edge. The junction boxes may further include a lid removably coupled to the top edge of the housing and a seal disposed on an outer surface of the bottom of the housing.

What is claimed is: 
     
       1. A junction box for a roof-mounted photovoltaic (PV) module, comprising:
 a housing comprising a plurality of sides, a bottom having a conduit through hole, and a top edge defining a top opening, 
 wherein the top edge comprises a lip disposed around the top edge and projecting upward from the top edge; 
 a lid removably coupled to the top edge of the housing; and 
 a seal disposed on and covering a majority of an outer surface of the bottom of the housing, wherein the seal is configured to contact a roof. 
 
     
     
       2. The junction box of  claim 1 , wherein the top edge forms a flange extending radially from the plurality of sides of the housing, the flange comprising a recess and a flange through hole disposed within the recess. 
     
     
       3. The junction box of  claim 2 , wherein the flange through hole is configured to receive a fastener. 
     
     
       4. The junction box of  claim 3 , wherein the lid comprises a lid through hole aligned with the flange through hole, wherein the flange through hole is configured to receive the fastener. 
     
     
       5. The junction box of  claim 1 , wherein the lip of the top edge is configured to mate with a recess in an underside of the lid. 
     
     
       6. The junction box of  claim 1 , further comprising:
 a conduit stub disposed concentric with the conduit through hole and extending downward from the outer surface of the bottom of the housing, 
 wherein the conduit stub is configured to be inserted into a hole in the roof. 
 
     
     
       7. The junction box of  claim 6 , wherein the conduit stub extends upward from an inner surface of the bottom of the housing. 
     
     
       8. The junction box of  claim 1 , further comprising a plurality of holes extending through the bottom of the housing,
 wherein the holes are each configured to receive a fastener to couple the housing to the roof. 
 
     
     
       9. The junction box of  claim 8 , wherein each of the holes of the plurality of holes extending through the bottom of the housing is surrounded by a rim extending upward from an inner surface of the bottom of the housing. 
     
     
       10. The junction box of  claim 1 , wherein the seal comprises butyl rubber. 
     
     
       11. The junction box of  claim 1 , wherein the seal comprises an adhesive surface. 
     
     
       12. The junction box of  claim 1 , further comprising a cable gland extending radially outward from a first side of the housing. 
     
     
       13. The junction box of  claim 1 , further comprising a plurality of holes extending through the seal,
 wherein the holes are each configured to receive a fastener to couple the housing to the roof. 
 
     
     
       14. A junction box assembly for a roof-mounted photovoltaic (PV) module, comprising:
 a junction box, comprising:
 a housing comprising a plurality of sides, a bottom, and a top edge defining a top opening; and 
 a lid removably coupled to the top edge of the housing; 
 
 a mounting bracket removably coupled to the bottom of the junction box and configured to couple the junction box with a mounting rail of a PV module mounting system; and 
 a grounding element disposed on a top surface of the mounting bracket, 
 wherein the grounding element is configured to form a grounding path from an interior of the junction box to the mounting rail. 
 
     
     
       15. The junction box assembly of  claim 14 , wherein the grounding element is disposed through an aperture in the bottom of the housing. 
     
     
       16. The junction box assembly of  claim 14 , wherein the mounting bracket comprises a pan portion configured to support the bottom of the junction box, an upright portion extending generally perpendicular to the pan portion, and a flange portion extending from the upright portion. 
     
     
       17. The junction box assembly of  claim 16 , wherein the flange portion is configured to engage a channel in an upper surface of the mounting rail to secure the mounting bracket to the rail. 
     
     
       18. A junction box for a roof-mounted photovoltaic (PV) module, comprising:
 a housing having a plurality of sides and a bottom; 
 a lid removably coupled to the housing; 
 a cable gland extending radially outward from a first side of the housing; 
 a conduit stub comprising an exterior portion extending downward from an outer surface of the bottom of the housing and an interior portion extending upward from an inner surface of the bottom of the housing, 
 wherein the exterior portion of the conduit stub is configured to be inserted into a hole in a roof; and 
 a seal disposed on the outer surface of the bottom of the housing. 
 
     
     
       19. The junction box of  claim 18 , further comprising a barrel portion disposed at a first corner formed by the first side of the housing and a second side of the housing, the barrel portion having a longitudinal hole configured to receive a fastener to couple the lid to the housing. 
     
     
       20. The junction box of  claim 19 , wherein the lid comprises a hole aligned with the longitudinal hole of the barrel portion, wherein the fastener is disposed through the hole. 
     
     
       21. The junction box of  claim 18 , wherein the exterior portion and the interior portion of the conduit stub together form a conduit through hole. 
     
     
       22. The junction box of  claim 18 , wherein the seal is spaced apart from and surrounds the conduit stub. 
     
     
       23. The junction box of  claim 18 , wherein the conduit stub is integral with the housing.